Covering arrangement such as a soft top for a motor vehicle

ABSTRACT

A covering arrangement such as a soft top for a motor vehicle comprises a surface element such as a soft top element connected to another structural element which is in the form of a second surface element, or a roof channel or gutter, or a window pane member, or a frame linkage assembly member. The first-mentioned surface element and the other structural element are connected together by means of a strip-shaped PUR-casting resin bead element.

CROSS REFERENCE TO RELATED APPLICATION

This application is a division of application Ser. No. 09/088,219 filedJun. 1, 1998 and now U.S. Pat. No. 6,082,807.

FIELD OF THE INVENTION

The present invention relates to a covering arrangement, more especiallyfor example a soft top for a motor vehicle. Such a top may also bereferred to as a drop head or cabriolet top.

BACKGROUND OF THE INVENTION

One form of a soft top for a motor vehicle comprises a soft top surfaceelement such as a portion of canvas or like material which is connectedto another structural element of the assembly which may be for example asecond soft top surface element which hitherto is generally sewn to thefirst soft top surface element. As an example in this respect referencemay be made to FIG. 2 of U.S. Pat. No. 3,028,194.

In order to seal off the sewn seams, such a soft top is usually sealedoff at the inside surface thereof in the region of the sewing, forexample by means of a suitable sealing material which can be applied byspreading or painting thereon. Sewing the soft top elements together andsealing them off along the common connecting seam represents a notinconsiderable amount of work and thus a significant cost factor.

OBJECTS OF THE INVENTION

An object of the present invention is to provide a soft top for a motorvehicle, which can be produced in a comparatively simple manner.

Another object of the present invention is to provide a soft top for amotor vehicle, such as to afford enhanced versatility in terms of designconfiguration.

Still another object of the present invention is to provide a soft topfor a motor vehicle which is of a simple but nonetheless functionallyreliable and acceptable nature involving a simple production procedureby virtue of its design.

SUMMARY OF THE INVENTION

In accordance with the principles of the present invention the foregoingand other objects are achieved by a soft top for a motor vehicle,including a first soft top surface element and a structural elementconnected thereto. The structural element comprises a second soft topsurface element and the first and second soft top surface elements areconnected together by a polyurethane casting resin bead element of stripconfiguration.

The abbreviation PUR will be generally used hereinafter to denotepolyurethane.

In another aspect of the present invention the foregoing and otherobjects are attained by a soft top for a motor vehicle, including afirst soft top surface element and a PUR-casting resin bead elementconnected to the first soft top surface element, the bead elementcomprising a roof channel or gutter as an integral component thereof.

In still another aspect of the invention the foregoing and other objectsare achieved by a soft top for a motor vehicle, including a first softtop surface element and a first structural element comprising a soft topwindow or rear window, and a PUR-casting resin bead element of stripconfiguration connecting the window and the soft top surface elementtogether.

In still a further aspect of the invention the foregoing and otherobjects are achieved by a soft top for a motor vehicle, including afirst soft top surface element and a first structural element comprisinga soft top frame linkage member, with a PUR-casting resin bead elementenclosing said linkage member and connected to said soft top surfaceelement.

As will be apparent from the description hereinafter of preferredembodiments of the soft top arrangement in accordance with the presentinvention, to produce such a soft top according to the invention it isonly necessary for the first soft top surface element and the otherstructural element co-operating therewith to be appropriately fittedinto a tool of a suitable configuration, for the tool to be sealinglyclosed, and for the PUR-casting resin to be introduced into a moldcavity defined by the tool in the closed condition. After reaction ofthe PUR-casting resin the casting mold defined by the tool can be openedand the corresponding soft top or soft top portion can be removedtherefrom. This procedure therefore affords the advantage that there isno need of a sewing operation to connect the components together and acoating operation for sealing off the sewn seam or seams. A furtheradvantage of the soft top designed in accordance with the invention isthat the result of the described operation, that is to say the castingprocedure, is very clean and neat and can be accurately reproduced atany time. Furthermore there is no need of especially qualified operatorsin order to produce the soft top in accordance with the invention. Ofcourse, the bead is then simultaneously applied to both the soft-top andthe structural elements.

In accordance with a preferred feature of the invention the first andsecond soft top surface elements are disposed in mutually alignedrelationship with each other for connection thereof. Likewise it ispossible in an alternative preferred feature for the second soft topsurface element to project away from the first soft top surface elementat a given angle which can be for example about 90°. It will be notedhowever that this angle may also be of any other suitable value,depending on the respective circumstances involved.

The PUR-casting resin bead element in strip form affords a firm strongconnection between the respectively associated components. The strengthof the connection between the associated soft top elements isadvantageously further improved in accordance with a preferred featureof the invention if, in a soft top according to the invention, themutually facing edges of the soft top surface elements are spaced fromeach other and are provided with anchoring holes, with the PUR-castingresin bead element covering over the edges of the soft top surfaceelements to a position over the anchoring holes. In that case thePUR-casting resin passes through the anchoring holes whereby themechanical strength of the connection between the cooperating soft topelements is correspondingly improved.

In a preferred feature of the soft top according to the invention thePUR-casting resin bead element covers the edges of the two soft topelements on both sides thereof. In that case the PUR-casting resin beadelement may be of an at least approximately symmetrical cross-sectionalprofile in relation to the soft top elements. It is however alsopossible for the bead element to be formed on one side with a hingegroove or channel, thereby defining a substantially kidney-shapedcross-sectional configuration constituting a hinge portion. Such aconstruction is used in particular where it is desirable for theinterconnected soft top elements to be folded together simply andaccurately as desired.

In a soft top for a motor vehicle with first and second adjacent softtop elements, it may be desirable if the edges of the first and secondsoft top elements are connected together by means of a strip-shapedconnecting element covered by the PUR-casting resin bead element. Inthat case the strip-shaped connecting element can be covered on one sideby the bead element so that the connecting element is visible from theother side, but it is also possible for the bead element to cover thestrip-shaped connecting element on both sides thereof so that the latteris invisible.

In accordance with another preferred feature of the invention thestrip-shaped connecting element referred to above can be formed by awoven or braided strip. Such a connecting element may be for example aglass fiber cloth portion, a metal braid portion or the like. It will beappreciated that the strip-shaped connecting element can also be in theform of a net or mesh portion. When the soft top according to theinvention includes strip-shaped connecting elements of that kind, whichcan be for example glued to the two soft top surface elements, it ispossible to avoid shrinkage in the region of the connection between thetwo soft top surface elements. When the reaction of the PUR-castingresin occurs, there is a shrinkage effect which can be of the order ofmagnitude of about 1%. By virtue of the provision of the above-mentionedstrip-shaped connecting element in the form of a woven or braided strip,it is possible to eliminate such a shrinkage effect and thus to providefor stabilization of the PUR-casting resin bead element. In that way itis possible for example to avoid undesirable fold formation in theconnecting region of the two soft top surface elements. The sameadvantageous results can also be achieved for example by thestrip-shaped connecting element being formed by a clamp strip or alattice strip from which press studs project at least on one sidethereof. Another advantageous feature of the invention provides that thestrip-shaped connecting element is formed by first and secondinterlocked or interlaced wire loop or wire corrugation elements.

It is also possible in accordance with another preferred feature of theinvention for the edges of the soft top surface elements to be providedalternately with anchoring holes and with anchoring portions which areengageable therein.

In regard to the configuration of the soft top in accordance with thepresent invention as outlined hereinbefore in which the bead elementcomprises a roof channel as an integral component thereof, to which thefirst soft top surface element is connected, such a design configurationaffords the advantage that the roof channel can be produced directly,which is desirable in terms of aspects relating to manufacture and thecosts arising therefrom.

In regard to the soft top construction according to the invention asoutlined above in which the first structural element comprises a windowconnected to the soft top surface element by means of the PUR-castingresin bead element, it will be noted that it is possible to use in thatcase as desired any PUR-casting resin system enjoying a given level ofhardness or softness. For example the PUR-casting resin system may havea shore hardness A of the order of magnitude of 60. As desired thePUR-casting resin system may be suitably colored and may have a lightfastness of between stages 6 and 7 in accordance with the GermanStandard DIN 75 002.

The soft top or rear window of the soft top arrangement according to theinvention can be glued into the PUR-casting resin bead element or can becast directly therewith.

In accordance with another feature of the invention the PUR-castingresin bead element can be produced by means of a single-phase castingprocess. It is however also possible for the PUR-casting resin beadelement to be produced in a two-phase casting process or a multi-phaseprocess, that is to say for example in a molding tool withinterchangeable mold portions or cover portions. That advantageouslypermits the implementation of a large number of different designconfigurations for the soft top. Furthermore it is possible for thePUR-casting resin bead element to be in the form of a surfacereinforcement or a surface stiffening means for a respective soft topsurface element. That also can be produced for example by a per se knownsingle-phase casting process or in a known two-phase or multi-phasecasting process. Different casting resins may be employed in suchprocesses.

Further objects, features and advantages of a covering arrangement morespecifically in the form of a soft top for a motor vehicle according tothe present invention will be apparent from the following description ofpreferred embodiments thereof.

BRIEF DESCRIPTION OF THE DRAWING

The above and other objects, features, and advantages will become morereadily apparent from the following description, reference being made tothe accompanying drawing in which:

FIG. 1 is a perspective view in partial section of part of a firstembodiment of a soft top according to the invention;

FIG. 2 is a similar view to FIG. 1 of a second embodiment of a soft topaccording to the invention;

FIG. 3 is a similar view to FIG. 1 of a third embodiment of the soft topaccording to the invention;

FIG. 4 is a similar view to FIG. 1 of a fourth embodiment of the softtop according to the invention;

FIG. 5 is a perspective view in section of part of a fifth embodiment ofa soft top according to the invention;

FIG. 6 is a perspective view in section of part of a sixth embodiment ofa soft top according to the invention;

FIG. 7 is a perspective view in section of part of a seventh embodimentof a soft top according to the invention;

FIG. 8 is a similar view to FIG. 7 of an eighth embodiment of a soft topaccording to the invention;

FIG. 9 is a similar view to FIG. 7 of a further alternative form of asoft top according to the invention;

FIG. 10 is a similar view to FIG. 7 of a tenth embodiment of a soft topaccording to the invention;

FIG. 11 is a similar view to FIG. 7 of an eleventh embodiment of a softtop according to the invention;

FIG. 12 is a perspective view in section of part of a twelfth embodimentof a soft top according to the invention;

FIG. 13 is a perspective exploded view of a thirteenth embodiment of asoft top according to the invention;

FIG. 14 is a perspective view in section of a part of the constructionshown in FIG. 13 in the assembled condition, and

FIG. 15 is a perspective exploded view of yet another embodiment of apart of a soft top according to the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

It will be noted that the FIGS. of the accompanying drawing arediagrammatic views of parts of embodiments of a soft top in accordancewith the invention.

Referring therefore firstly to FIG. 1, shown therein in section is partof a first embodiment of an arrangement according to the invention inthe form of a soft top as indicated at 10 for a motor vehicle, inparticular for a private motor vehicle, comprising a first soft top,surface element 12 and another structural element as indicated at 14which is also formed by a second soft top surface element. As the secondsoft top surface element is the same or similar to the first soft topsurface element 12, the second soft top surface element is alsoindicated by reference numeral 12 in the drawing. The first and secondsoft top surface elements 12 are disposed in mutually alignedrelationship. The mutually facing edges as indicated at 16 thereof areat a small spacing from each other and are each provided with anchoringholes as diagrammatically indicated at 18. It will be appreciated thatthe edges 16 of the soft top surface elements 12 may also be disposed inmutually overlapping relationship.

The two soft top surface elements 12 are mechanically firmly andsealingly connected together by means of a PUR-casting resin beadelement as indicated generally at 20, of an elongate strip-shapedconfiguration. The bead element 20 covers over the edges 16 of the softtop surface elements 12 to a position over the anchoring holes 18, andit is of such a configuration that it affords an at least approximatelysymmetrical cross-sectional profile in relation to the mutually alignedsoft top surface elements 12.

Reference will now be made to FIG. 2 showing an embodiment, which isgenerally similar to that shown in FIG. 1, for which reason the sameparts and components are indicated in FIG. 2 by the same references asthose used in FIG. 1. It will be seen from FIG. 2 that the embodimentillustrated therein has a PUR-casting resin bead element 20 which isformed on one side with a hinge groove or channel 22, thus imparting asubstantially kidney-shaped cross-sectional configuration to the beadelement 20 which thus constitutes a form of hinge portion to permitpivotal movement of the soft top surface elements 12 relative to eachother about the hinge groove or channel 22.

Referring to FIG. 3, shown therein is a part of a soft top 10 with afirst soft top surface element 12 and another structural element 14which is also formed by a second soft top surface element 12, whereinthe two soft top surface elements 12 are aligned with each other and areconnected together by means of a connecting element 24 of strip-shapedconfiguration. The strip connecting element 24 can be formed for exampleby a textile woven cloth or braid as indicated at 26 which is securedfor example by sewing or gluing to the edges 16 of the two adjacent softtop surface elements 12. The connecting element 24 is disposed at theinside of the soft top 10. Provided on the outside of the soft top 10 isthe PUR-casting resin bead element 20 which covers over the edges 16 ofthe soft top surface elements 12. In the FIG. 3 embodiment of the softtop 10 the edges 16 are also provided with spaced-apart anchoring holes18 which are covered over by the PUR-casting resin bead element 20.

FIG. 4 shows an embodiment of the soft top 10 in which a soft topsurface element 12 is combined with another structural element 14 formedby a frame assembly linkage member 28 of the soft top 10. The member 28is mechanically firmly and sealingly connected to the soft top surfaceelement 12 by means of a PUR-casting resin bead element 20. For thatpurpose the edge 16 of the soft top surface element 12 is for exampleagain provided with spaced-apart anchoring holes diagrammaticallyindicated at 18. The bead element 20 covers the edge 16 of the soft topsurface element 12 to such an extent that the anchoring holes 18 arecovered by the bead element 20. It will be clear from FIG. 4 that themember 28 is enclosed by the bead element 20 which for example is casttherearound.

Referring now to FIG. 5, shown therein is an embodiment of the soft top10 wherein a soft top surface element 12 is combined with anotherstructural element 14 formed by a soft top or rear window of which apart is diagrammatically indicated at 30. The soft top or rear window 30is mechanically firmly and sealingly connected to the soft top surfaceelement 12 by means of a PUR-casting resin bead element 20. The beadelement 20 mechanically firmly and sealingly embraces the edges 16 ofthe soft top surface element 12 and the edge 32, which is adjacentthereto, of the window 30, at both sides thereof, that is to say both onthe inside and the outside thereof.

Reference is now made to FIG. 6 showing an embodiment of the soft top 10in which a soft top surface element 12 is directly combined with a roofchannel or gutter of which a part is diagrammatically indicated at 34.In that arrangement the roof channel 34 is an integral component of anelongate strip-shaped PUR-casting resin bead element 20 which ismechanically firmly and sealingly fixed to the edge 16 of the soft topsurface element 12. In this case therefore the roof channel 34 forms theother structural element 14, which has already been referred to on anumber of occasions hereinbefore as constituting part of the soft toparrangement according to the invention.

Referring now to FIG. 7, shown therein is part of an embodiment of asoft top 10 according to the invention with a soft top surface element12 from which a second soft top surface element 12 projects away at anangle for example of 90°. The second soft top surface element 12 thusconstitutes the other structural element 14 which has already beenreferred to hereinbefore. The two soft top surface elements 12 aremechanically firmly and sealingly connected by means of an elongatestrip-shaped PUR-casting resin bead element 20 which is formed with twoconcave fillet portions as indicated at 36.

FIG. 8 shows an embodiment of a soft top 10 according to the inventionwith first and second soft top surface elements 12, similarly to FIGS.1, 2 and 3. FIG. 8 also shows that a strip-shaped connecting element 24is mounted to or fixed to the mutually adjacent edges 16 of the soft topsurface elements 12 which are disposed at a slight spacing from eachother. The connecting element 24 is formed for example by a woven orbraided strip as indicated at 38. The strip 38 is covered over by astrip-shaped PUR-casting resin bead element 20 by means of which thefirst and second soft top surface elements 12 are firmly and sealinglyconnected together. The strip 38 is covered over by a strip-shapedPUR-casting resin bead element 20 by means of which the first and secondsoft top surface elements 12 are firmly and sealingly connectedtogether. The strip 38 provides for eliminating the contraction effectcaused by shrinkage of the PUR-casting resin bead element 20, of theorder of magnitude of about 1%, so that fold formation caused byshrinkage of the bead element 20, along the edges of the soft topsurface elements 12, can be reliably prevented in that simple fashion.The bead element 20 can cover over the edges 16 of the first and secondsoft top surface elements 12 at one side or preferably both sidesthereof, in a suitable fashion.

Referring to FIG. 9, shown therein is part of an embodiment of the softtop 10 according to the invention, which differs from the embodimentillustrated in FIG. 8 in particular insofar as the strip-shapedconnecting element 24 between the two soft top surface elements 12 isformed by a clipping or clamping strip as diagrammatically indicated at40, which for example comprises a suitable plastic material. Theclipping strip 40 can be of such a configuration that in this case alsoshrinkage and thus folding along the edges 16 of the soft top surfaceelements 12 is at least very substantially prevented. An elongatestrip-shaped PUR-casting resin bead element 20 also covers over theedges 16 of the soft top surface elements 12 and the strip-shapedconnecting element 24 which couples the edges 16 together, in theconfiguration of the virtually endless clipping strip 40.

FIG. 10 shows a further embodiment of a soft top 10 according to theinvention in which first and second soft top surface elements 12 areformed along their mutually facing edges 16 alternately with anchoringholes 42 and anchoring portions 44 which can be respectively fittedtherein. The anchoring portions 44 can form integral components of thesoft top surface elements 12. In this embodiment also the soft topsurface elements 12 are mechanically firmly and sealingly joinedtogether by means of an elongate strip-shaped PUR-casting resin beadelement 20.

Looking at FIG. 11, the embodiment illustrated therein of a soft top 10according to the invention combines a soft top surface element 12 withanother structural element 14, being therefore firmly and sealinglyconnected thereto. The element 14 is formed for example by a fixingstrip 46 of plastic material. The element 14 can, for example, also havepress studs, snap catches, a hook-and-loop strip or the like. It ismechanically firmly and sealingly connected to the soft top surfaceelement 12 by a two-component casting process in which two suitablecasting mold halves or portions are successively used in order in afirst molding step to produce a first component 48 and immediatelythereafter in the same molding tool a second component 50 which aremechanically firmly and sealingly connected to each other and to thesoft top surface element 12 and the other element 14 and which togetherform the PUR-casting resin bead element 20.

FIG. 12 is a diagrammatic view of part of an embodiment of a soft top 10according to the invention comprising first and second mutually alignedsoft top surface elements 12 which are mechanically firmly and sealinglyconnected together by means of a PUR-casting resin bead element 20. Thesoft top surface element 12 which is shown on the right-hand side inFIG. 12 is provided with a PUR-casting resin surface reinforcement 52while the element 12 of which part is shown on the left-hand side inFIG. 12 is provided with a PUR-casting resin surface stiffening means54.

Referring now to FIGS. 13 and 14, illustrated therein is a furtherembodiment of a soft top 10 according to the invention comprising firstand second mutually aligned soft top surface elements 12 which areprovided with anchoring holes 18 along their respective mutually facingedges 16. Provided for mechanically connecting the adjacent soft topsurface elements 12 is a strip-shaped connecting element 24 formed by alattice strip 56 from which press studs 58 project at both sidesthereof. As can be clearly seen from FIG. 14, the press studs 58 on theupper side of the lattice strip 56 are passed through the anchoringholes 18 at the edges 16 of the two soft top surface elements 12,whereupon the two soft top surface elements 12 are mechanically firmlyand sealingly connected to a PUR-casting resin bead element 20, therebycovering over the edges 16. The press studs 58 which project from thelattice strip 56 at the underside thereof serve in particular for firmlyanchoring the lattice strip 56 to the PUR-casting resin bead element 20.A certain hinge effect can also be achieved in the case of thisstructure by virtue of the substantially kidney-shaped cross-sectionalconfiguration of the PUR-casting resin bead element 20.

FIG. 15 diagrammatically illustrates a soft top 10 comprising first andsecond soft top surface elements 12, wherein a strip-shaped connectingelement 24 for connecting the elements 12 together is formed by two wireloop elements or wire corrugation elements which are diagrammaticallyindicated at 60. The wire loop or wire corrugation elements 60 of thetwo elements 12 are interlocked or interlaced with each other, therebyto interconnect the adjacent elements 12 in mutually alignedrelationship.

It will be readily apparent from the above-described alternativeconfigurations of a structure and arrangement according to the inventionthat a complete vehicle soft top can be produced in accordance with theinvention without involving sewing and without a sealing operationfollowing sewing, in a simple, inexpensive, accurate and reproduciblemanner.

It will further be noted at this point that the invention is not limitedmerely to a soft top for a motor vehicle, but it can also be used in thesame and a similar manner in relation to weather-protection and coveringarrangements generally such as tents, heavy goods vehicle or truckcovers and the like.

It will be appreciated that the above-described embodiments andconfigurations according to the invention have been described solely byway of example and illustration thereof and that it is possible toimplement a large number of alternative configurations using simple andrelatively inexpensive means so that various modifications can be madein the illustrated embodiments without thereby departing from the spiritand scope of the invention.

We claim:
 1. A soft top assembly for an automotive vehicle consistingessentially of: a soft top surface element having an edge and formedalong said edge with spaced-apart anchoring holes; a frame assemblylinkage element in the form of a circular cross section tube extendingalong said edge and lying substantially in a common plane with saidedge; and a strip-shaped polyurethane cast resin bead elementsurrounding said tube and embedding said edge and passing through saidholes, said strip-shaped polyurethane cast resin bead element bridging agap between said tube and said edge and having a continuously convexcontour on one side of said surface element and a concave fillet contouron an opposite side of said surface element.
 2. The soft top assemblydefined in claim 1 wherein said polyurethane cast resin bead element iscomposed of a two-component polyurethane.